Unitary carton and reusable shipping package therefor



Nov. '17, 1970 L. H. KIRK 3,541,052

UNITARY CARTON AND REUSABLE SHIPPING PACKAGE THEREFOR Filed Oct. 15, 1968 v v 2 Sheets-Sheet 1 FIG. I Q l4 v 24 -2s f p4) F :,m as

' (b ZBLIS 3 I9 26 7 72:53:53; 2555117 INVENTQRV 1 I 5 BY diam SH. KIRK 7 u 94c 1 9%, I 98 MO Nov. 17, 1970 1.. H. KIRK 3,541,052

UNITARY CARTON AND REUSABLE SHIPPING PACKAGE THEREFOR PM Oct. 15, 1968 2 Sheets-Sheet 2 F I 4 [66a Am-A 1 &

INVENTOR MS TORNEYS United States Patent O US. Cl. 206-65 8 Claims ABSTRACT OF THE DISCLOSURE A carton having a unitary body and a plurality of relatively foldable panels includes a base panel, side panels adjacent opposite marginal edges of the base panel which in turn include two relatively foldable portions, and end panel adjacent a third marginal edge of the base panel, and a cover panel adjacent the end panel; the surface of a portion of each side panel has at least one opening and the surface of the cover panel has at least two integral tabs which register with the respective side panel openings when the carton is assembled by folding the several panels with respect to each other, the tabs being bendable out of the surface plane of the cover panel and into the respective openings in the side panels to constrain the several panels in their relatively folded positions; a plurality of cartons may be transported in a reusable shipping package which includes a rigid base upon which the cartons are arranged in a suitable number of stacks and secured, a unitary cover sheet of substantial thickness which includes a first por tion underlying the base and second and third portions foldable into surface contact with opposite lateral carton stacked faces, and fastening means for securing the cover sheet to the carton stacks.

The present invention relates to cartons and shipping packages. More particularly, the present invention relates to a novel construction of a carton having a unitary body and a plurality of relatively foldable panels and a reusable shipping package for transporting a plurality of cartons of this type.

Unitary body cardboard or fiberboard cartons having a plurality of relatively foldable panels are well known. Cartons of this type are generally fastened together by staples or rivets and, in some cases by complex tab and slit configurations which are difficult to manipulate. In addition, shipment of a plurality of such cartons generally involves the time-consuming procedure of packing bulky wooden crates which are not suitable for reuse. The heavy shipping crates have the further drawback of increasing the freight charges incurred by the shipper and thus add to the cost of the article being shipped. Particularly in the packaging and shipping of metallic refrigeration tubing, wire cable and the like, a lightweight, sturdy carton which is easy to assemble and a lightweight, preferably reusable shipping package for transporting a plurality of cartons has not been available.

SUMMARY OF THE INVENTION The carton of the present invention is of the type having a unitary body and a plurality of relatively foldable panels. The present carton comprises a rectangular base panel, first and second side panels adjacent first and second opposite edges of the base panel, each side panel including first and second relatively foldable portions, a first end panel adjacent a third marginal edge of the base panel, and a rectangular cover panel adjacent the first end panel. The surface of the second portion of each side panel has at least one opening and the surface of the cover panel has at least two integral tabs which are bendable out of the surface plane of the cover panel. The tabs register with respective side panel openings when the side panels and the first end panel are folded at substantially a right angle with respect to the base panel, the second portions of the side panels are folded at substantially a right angle with respect to the first portions of the side panels, and the cover panel is folded into surface contact with the second portions of the side panels. The several panels are constrained in their relatively folded positions by displacing the tabs of the cover panel into the respective openings in the second portions of the side panels.

A plurality of cartons may be transported in the reusable shipping package of the present invention which comprises a rigid base, the cartons being arranged in a stack and secured to the base. A unitary cover sheet of substantial thickness includes a first portion which underlies the base and second and third portions which are foldable with respect to the first portion into surface contact with opposite lateral carton stack faces. The cover sheet is secured to the carton stacks by fastening means which are disposed about the carton stack and the second and third portions of the cover sheet.

The carton and shipping package of the present invention offer the advantages of rapid assembly which reduces labor costs and light weight which reduces shipping costs.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a unitary body sheet of a first embodiment of the carton of the present invention;

FIG. 2 is a perspective view in partial section of a first embodiment of the carton of the present invention;

FIG. 3 is a sectional view taken substantially along line 33 of FIG. 2;

FIG. 4 is a plan view of a unitary body sheet of a second embodiment of the container of the persent invention;

FIG. 5 is a perspective view in partial section of the second embodiment of the carton of the present invention;

FIG. 6 is an elevation of the shipping package of the present invention;

FIG. 7 is a perspective view of the shipping package of the present invention; and

FIG. 8 is a perspective view of the reusable cover sheet of the shipping package of the present invention in folded condition.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring particularly to FIGS. 1 through 3, a first embodiment of the present carton comprises a pre-cut, unitary body sheet 10 of a rigid or semi-rigid material such as 200 lb. test B or C flute board or other material of suitable strength. The body sheet 10 has a plurality of relatively foldable panels including a rectangular base panel 11 which may be provided with a central opening 12 for convenience in hand carrying a carton containing coiled metallic tubing or wire as shown by broken lines in FIG. 1.

First and second side panels, 14 and 15 respectively, are adjacent first and second opposite marginal edges 16, 17 of the base panel 11; the edges 16, 17 are scored to enable the first and second side panels 14, 15 to be foldable with respect to the base panel 11. Each side panel 14, 15 includes first and second portions 18, 19 and 21, 22 respectively which are foldable with respect to each other along scores 24, 25. The second portions 19, 22 of the side panels 14, 15 are further provided with openings 26, 26a, and 27, 27a respectively, the purpose of which shall be explained, infra.

A first end panel 28 is adjacent a third marginal edge 29 of the base panel 11 and a second end panel 31 is adjacent a fourth marginal edge 32 of the base panel 11. The third and fourth marginal edges 29, 32 are scored to permit the first and second end panels 28, 31 to be folded with respect to the base panel 11. The second end panel 31 includes a first portion 33 and a second portion 34 which are relatively foldable along score 35. The second portion 34 of the second end panel 31 is further provided with openings 36 and 36a.

A rectangular cover panel 39 adjacent the first end panel 28 is relatively foldable with respect thereto along score 41. The cover panel 39 has a central opening 42 which, as in the case of opening 12 in the base panel 11, is provided for convenience in hand carrying the carton and includes four integral tabs 44a through 44d, inclusive, which may be formed by die cutting or other suitable method and which are bendable out of the surface plane of the cover panel 39.

To fashion the body sheet of FIG. 1 into a completed carton 46 as shown in FIG. 2, the first and second side panels 14, 15 and the first and second end panels 28, 31 are folded at substantially right angles with respect to the base panel 11 along the scored marginal edges 16, 17, 29 and 32, respectively. Next, the second portion 34 of the second end panel 31 is folded along score at substantially a right angle with respect to the first portion 33 and the second portions 19, 22 of the side panels 14, 15 are folded along scores 24, 25 at substantially a right angle with respect to the first portions 18, 21 into surface contact with the second portion 34 of the second end panel 31. The cover panel 39 is then folded with respect to the first end panel 28 along score 41 into surface contact with the second portion 34 of the second end panel 31. The several panels having been folded as described above, tab 44a of the cover panel 39 registers with opening 26 of the second portion 19 of the first side panel 14 and opening 36 of the second portion 34 the second end panel 31 tab 44b registers with opening 26a of the second portion 19 of the first side panel 14, tab 44c registers with opening 27 of the second portion 22 of the second side panel 15 and opening 36a of the second portion 34 of the second end panel 31, and tab 44d registers with opening 27a of the second portion 22 of the second side panel 15. The tabs 44a through 44d, inclusive, are displaced into the respective openings in the second portions 19, 22 of the second side panels 14, 15 and in the second portion 34 of the second end panel 31 to constrain the several panels in their respective folded positions.

Referring now to FIGS. 4 and 5, an alternate embodiment of the present carton comprises a pre-cut, unitary body sheet 50 of a rigid or semi-rigid material such as 200 lb. test B or C flute board or other material of suitable strength. The body 50 has a plurality of relatively foldable panels including a rectangular base panel 51 which may be provided with a central opening 52 for convenience in hand carrying the carton.

First and second side panels, 54 and 55 respectively, are adjacent first and second opposite marginal edges 56, 57 of the base panel 51; the edges 56, 57 are scored to enable the first and second side panels 54, 55 to be foldable with respect to the base panel 51. Each side panel 54, 55 includes first and second portions 58, 59 and 61, 62 respectively which are foldable with respect to each other along scores 64, 65. The second portions 59, 62 of the side panels 54, 55 are further provided with openings 66, 66a and 67, 67a.

A first end panel 68 is adjacent a third marginal edge 69 of the base panel 51, the third marginal edge 69 being scored to permit the first end panel 68 to be folded with respect to the base panel 51.

A rectangular cover panel 71 adjacent the first end panel 68 is relatively foldable with respect thereto along score 72. The cover panel 71 has a central opening 73, which as in the case of opening 52 in the base panel 51, and openings 12 and 42 of the carton 46 of the first embodiment, is provided for convenience in hand carrying the carton. The cover panel 71 includes four integral tabs 740 through 74d, inclusive, which may be formed by die cutting or other suitable method and which are bendable out of the surface plane of the cover panel 71.

In the embodiment of FIGS. 4 and 5, a second end panel 76 is adjacent a scored marginal edge 77 of the cover panel 71. The second end panel includes a first portion 78 and a second portion 79 which are relatively foldable along score 81. Unlike the second portion 34 of the second end panel 31 of the carton 46 illustrated in FIGS. 1 through 3, the second portion 79 of the second end panel 76 is not provided with openings.

To fashion the body sheet of FIG. 4 into the completed carton 82 of FIG. 5, the first and second side panels 54, and the first end panel 68 are folded at substantially a right angle with respect to the base panel 51 along the scored marginal edges 56, 57 and 69, respectively. Next, the second portions 59, 62 of the respective side panels 54, 55 are folded along scores 64, at substantially a right angle with respect to the first portions 58, 61 and the cover panel 71 is folded with respect to the first end panel 68 along score 72 into surface contact with the second portions 59, 62 of the side panels 54, 55. The several panels having been folded as described above, openings 66, 66a of the second portion 59 of the first side panel 54 register with tabs 74a and 74b, respectively, of the cover panel 71, and openings 67 and 67a of the second portion 62 of the second side panel 55 register with tabs 74c and 74d, respectively, of the cover panel 71. The tabs 74a through 74d, inclusive, are displaced into the respective openings in the second portions 59, 62 of the side panels 54, 55 to constrain the several panels in their relatively folded position. The carton 82 may be completed by folding the first portion 78 of the second end panel 76 at substantially a right angle with respect to the cover panel 71 along the score 77, folding the second portion 79 of the second end panel 76 at substantially a right angle with respect to the first portion 78 along score 81, and tucking the second portion 79 between the base panel 51 and cover panel 71 and into surface contact with the base panel 51 as shown in FIG. 5.

Referring now to FIGS. 6 and 7, a plurality of cartons such as those illustrated in either FIG. 2 or FIG. 5 may be packed with suitable contents such as metallic tubing and shipped to a remote location in a reusable package which comprises a rigid base 88 for supporting a plurality of cartons which are arranged in stacks 89, 91 and secured to the base 88 by steel straps 92, 93, respectively, or other suitable means. The base 88 preferably is a wooden pallet of the type which includes spaced parallel beams 94a, 94b, 94c fastened together by a plurality of transverse slats 95 and is of sufficient size and strength to accommodate and support the carton stacks 89, 91. Where packaging of more than one stack of cartons is contemplated, a divider 96 of fiber board or other suitable material of substantial thickness is inserted between and separates adjacent carton stacks which are arranged side by side.

A unitary cover sheet 97, preferably of 1100 lb. test triple-wall fiber board or other suitable material of substantial strength and thickness includes a first portion 98 which underlies the base 88 and second and third portions 99, 101, respectively which are foldable with respect to the first portion along scores (not shown) into surface contact with opposite lateral carton stack faces as shown best in FIG. 7. A strap 102 or other suitable fastening means is disposed about the carton stack or stacks, as the case may be, and the second and third portions 99, 101 of the cover sheet 97 to secure the cover sheet 97 to the carton stacks. Upon arrival at its destination and upon disassembly and removal of the cartons, the cover sheet 97 may be folded flat as shown in FIG. 8, stacked together with a number of bases 88 and retained for eventual reuse if desired.

I claim:

1. A carton for spirally coiled tubing, cable and the like of the type having a unitary body and a plurality of relatively foldable panels comprising a rectangular base panel, first and second side panels adjacent first and second opposite marginal edges of the base panel, each side panel including first and second relatively foldable portions, a first end panel adjacent a third marginal. edge of the base panel, and a rectangular cover panel adjacent the first end panel, the cover panel having substantially the same overall dimensions as the base panel; the surface of the second portion of each side panel having at least one opening and the surface of the cover panel having at least two integral tabs which register with respective side panel openings when the side panels and the first end panel are folded at substantially a right angle with respect to the base panel, the second portions of the side panels are folded at substantially a right angle with respect to the first portions of the side panels, and the cover panel is folded into surface contact With and overlies substantially completely the second portions of the side panels; the tabs being bendable out of the surface plane of the cover panel and into the respective openings in the second portions of the side panels to constrain the several panels in their relatively folded positions.

2. A carton according to claim 1 further including a second end panel adjacent a fourth marginal edge of the base panel, the second end panel including first and second relatively foldable portions.

3. A carton according to claim 2 wherein the surface of the second portion of the second end panel has openings which register with openings in the surface of the second portions of the first and second side panels when the first portion of the second end panel is folded at substantially a right angle with respect to the base panel, the second portion of the second end panel is folded at substantially a right angle with respect to the first portion of the second end panel, and the second portions of the first and second side panels are folded into surface contact with the second portion of the second end panel.

4. A carton according to claim 3 wherein the second portions of the first and second side panels and the second portion of the second end panel each have two openings and the cover panel includes four integral tabs.

5. A carton according to claim 1 further including a second end panel adjacent a marginal edge of the cover panel, the second end panel including first and second relatively foldable portions.

6. A carton according to claim 5 wherein the second portion of each side panel has two openings and the cover panel includes four integral tabs.

7. A carton of the type having a unitary body and a plurality of relatively foldable panels comprising a rectangular base panel, first and second side panels adjacent first and second opposite marginal edges of the base panel, each side panel including first and second relatively foldable portions, a first end panel adjacent a third marginal edge of the base panel, and a rectangular cover panel adjacent the first end panel, the cover panel having substantially the same overall dimensions as the base panel; the surface of the second portion of each side panel having at least one opening and the surface of the cover panel having at least two integral tabs which register with respective side panel openings when the side panels and the first end panel are folded at substantially a right angle with respect to the base panel, the second portions of the side panels are folded at substantially a right angle with respect to the first portions of the side panels, and the cover panel is folded into surface contact with and overlies substantially completely the second portions of the side panels; the tabs being bendable out of the surface plane of the cover panel and into the respective openings in the second portions of the side panels to constrain the several panels in their relatively folded positions, the carton containing a spirally coiled elongated member.

8. A reusable shipping package comprising a rigid base for supporting a plurality of cartons, the cartons being arranged in at least two stacks side-by-side, each stack being secured to the base, a divider of substantial thickness inserted between and separating adjacent carton stacks, a unitary cover sheet of substantial thickness including a first portion underlying the base and second and third portions foldable with respect to the first portion into surface contact with opposite exposed lateral carton stack faces, and fastening means disposed about the carton stacks and the second and third portions of the cover sheet for securing the cover sheet to the carton stacks.

References Cited UNITED STATES PATENTS 1,707,680 4/1929 Norwood 229-36 2,065,650 12/ 1936 Burke. 2,973,858 3/1961 Laneve et al. 3,246,744 4/ 1966 Marnon 214-l0.5

FOREIGN PATENTS 1,086,846 4/1954 France.

WILLIAM T. DIXSON, JR., Primary Examiner US. Cl. X.R. 20652; 22936 

